Is there a lot of engineering required to move from AC410 to AC800M?
I have a network with 8 AC410 controllers and i intend to do a phased upgrade to AC800M.
How much engineering is involved with this migration interms of hardware and software.
Just wondering if hardware in this case would cost more than the engineeing prices? Am also wondering what the engineering entails?
If you are an ABB employee you can contact ABB BU Control Technologies Sales Support for Sales and commercial Support on Advant Master world wide, using this link:
ABB have different solutions for application conversion from AC410 & AC450 to AC800M depending on application.
You shall also be able to contact your regional ABB contact who shall have the knowledge to direct you to correct people for best upgrade advise.
ABB Control Technologies
Our company has successfully completed several upgradation projects of AC450, AC110 and APC controllers.
Let me share my experience how much engineering efforts it takes to upgrade AC450/AC410.
Upgradation consits of 4 steps:
1.) Hardware upgrade to AC800M
Thorough hardware detailed engineering may take couple of months.
Do you consider to reuse existing S800 or S100 IO cards?
In this case AF100 bus is to be replaced by Profibus. CI810 to be replaced by CI801 or CI840. New DSBC176 cards should be installed if S100 IO cards are reused.
AF100 coaxial cable must be replaced by new Profibus cable. Existing AF100 twisted pair cable may be reused for Profibus.
MB300 bus is beeing replaced by Ethernet network.
If your AC410 controllers are distributed in distant locations, fiber optic ring connected by ABB branded switches is a very reliable solution.
2.) Control logic migration
I use to use Ampl2m dot com tool for automated translation of Advant controller's code to AC800M. Its main advantages are:
- Automated translation saves a lot of SW engineering efforts (it saves 60-95% of time required for manual translation "from scratch").
If original code uses standard features of Valvecons, Motcons, Pidcons then automated translation produces nearly working code.
- It prevents human errors, typos
- Automated conversion utilises SW solutions already verified in successful migration projects
- Translation tool performs code optimisation in terms of bypassing spare terminals and dummy logic gates.
1 AC410 automated translation may take 3-4 weeks including all necessary manual fixes.
Amount of manual workaround depends on how sophistically and tricky is original AC410 code written.
3.) HMI graphics migration from AS500 to 800xA PG2
800xA installation takes about 2 weeks. One graphic can be converted and manually fixed within 4-6 hours.
Migration of graphics if special graphical libraries are used in AS500 (like RMC) is quite tricky.
4.) Thorough testing of translated code is highly recommended for smooth commissioning
There are 3 possible scenarios:
- Cost saving project without testing: This case brings a lot of risk of surprises during commissioning. Most likely this scenario leads to shutdown extension and delays in production.
- Testing of translated code of new AC800M controllers in simulation mode at test field. The best option is testing with AC410 in parallel.
The test of one AC410 should take at least 2-3 weeks to test all sequences, interlocks of motors, valves, direction of PID controls, communications...
- Shadowing is a parallel run of AC410 & AC800M controllers during production sharing the same IO input signals.
The purpose of shadowing is thorough comparison of output signals from old&new logic.
If the shadowing is applied during migration then your 8 AC410 can be replaced by AC800M within one week shutdown if original IOs are reused.
Our company can send you quotation if you are interested.
Post your automation layout.
I hope it helps